Evaporative cooler with tower air flow



March 5, 1957 c. H. w. KAHL EVPORTIVE COOLER WITH TOWER AIR FLOW FiledJan. 27, 19.55

2 Sheets-Sheet l March 5, 1957 c. H. w. KAHL EVAPORATIVE COOLER WITHTOWER AIR FLOW Filed Jan. 27, 1955 2 Sheets-Sheet 2 WMA/me United StatesPatent 2,783,982 EVAPORATIVE COOLER WITH TOWER All? FLQ'W Carl H.Wiliiam Kahl, Phoenix, Ariz. Application January 27, 1955, Serial No.484,435 3 Claims. (Cl. 261-24) This application is a continuation inpart of my two prior applications, Ser. No. 392,348, tiled Nov, i6,i953, and Ser. No. 448,096, filed Aug. 5, 1954, both for EvaporativeCooler With Tower Air Flow, and both now abandoned.

This invention relates to a type of air-treating apparatus generallyknown as an evaporative cooler.

Most present-day evaporative coolers are equipped with three moistenedlilter packs through which air is drawn by a blower. Some fifty cubicfeet of air per second pass through these filter packs, the thickness ofwhich is not more than a mans wrist. There is a possibility that some ofthe air may sweep through these thin packs without making satisfactorywiping contact.

Wood shavings are chosen as the cheapest and best suited material for atightly packed lter panel. However, wood shavings disintegrate in oneseason; mineral sediment, dust, and a form of algae, clogging up thepores. The packing has to be torn out and replaced with fresh material.Packs of metal shavings will also clog up.

Wood shaving material in filter packs is bound to sag as the water dripson it, and then weak spots develop. The suction of the blower,responding to the line of least resistance, exerts its drawing powerprimarily upon the thinnest section of a panel, favoring the centers ofthe two side panels. It is possible that the third iilter pack, in therear, may not get its full quota of air intake.

In View of the foregoing, one objective of my invention is to provide anevaporative cooler affording a longerdrawn-out travel of the air overmoistened surfaces.

Another object is to obtain cooling by forcing the air to wipe overmoistened surfaces that cannot sag.

Another objective is to construct an all-metal device which will beoperable through the years without requiring the seasonal tear-downs andreplacements of the filter packs.

Another objective is to add a device which will precool the intake waterbefore the intake air touches it.

Still another objective is to avoid drawing into this cooler theexcessively hot air of the outside and, instead, provide a ductconnection to the dwelling for the intake air, resulting in thecirculation of the house air.

Briefly stated, this device consists of a square top casing, open at thebottom, having an air outlet and a duct leading therefrom into adwelling to be cooled; a blower and a motor positioned inside; a towerunit shaped like the top casing, attached to the open bottom of the topcasing.

Corrugated metal sheets, their furrows positioned horizontally, are hungupon anges in the tower unit. V- trough humidifers are used to moistenthe rondures of the corrugated metal sheets over which the intake air isdrawn up through the open bottom of the tower unit.

To obtain circulation of the house air, an elbow duct is connected tothe open bottom of the tower unit, then a duct connection through a holein the dwelling.

I attain the aforementioned objectives by means of the devices andconstructions illustrated in the accompanying drawings, in which- Fig. lis a plain view in side elevation of the cooler installed on the side ofa dwelling.

Fig. 2 is a plain view in side elevation of the cooler installed atceiling height of a dwelling. It shows elbow duct connection to a houseduct for the circulation of the house air.

Fig. 3 gives a plain view of an emergency water outlet valve.

Fig. 4 is a plain view of a metal disk with slots and gable rooets usedfor the precooling of the intake water.

Fig. 5 is a perspective view of the rectangular trough of the waterdistribution section. Perforated V-troughs are attached, leading off atright angles from the main trough.

Fig. 6 gives a perspective view of the tower unit, open at the rear,with one corrugated metal sheet hung upon the flanges.

Fig. 7 isa perspective top view of the cut edges on top of eachcorrugated sheet..

Fig. 8 presents a perspective view of a spacer metal clip.

Fig. 9 gives a perspective view in side elevation of three corrugatedmetal sheets with spacers.

Referring to the drawings, Fig. 1 presents the apparatus asembled ofsheet metal, consisting of a top casingk A and a tower unit B. The towerunit B is attached to the open bottom of the top casing A.

The apparatus is installed `and connected to a dwelling C, by means ofbracket 24 and by duct 2 at the air outlet opening.

Top casing A is square in shape, closed on the top and onall four sides,except for air outlet 2. A blower 1 and a motor 3 are positioned withinthe` casing. The tower unit B, of similar shape, is connected to theopen bottom of top casing A. The rear side of tower unit E and Gisremovable.

Arrows 34 are inserted in Fig. 1 to indicate the direction of the airflow.

Fig. 2 shows the apparatus installed at ceiling height of a dwelling D.The cooler is supported by air outlet duct 4 and by air intakev duct 25.Top casing F is square in shape, closed on all sides and on top, exceptfor the outlet duct 4. A blower 45 and a motor 56 are installed withinthe casing. Tower unit G, of similar shape, is connected to the openbottom of top casing F. Arrows 47 indicate the direction of the air ow.

In tower unit G, as in tower unit B (Fig. l), angle-iron flanges 37 arefastened within, one near the top and one near the bottom of each side,for the insertion of corrugated metal sheets 5.l Slots 35 are cut in thesides of these sheets 5, one near the top and one near the bottom ofeach side, to fit upon the flanges 37.

Spacers 3S, fastened to top and bottom side edges of the corrugatedsheets 5, are metal clips with ends protruding at right angles. Thesespacers 38 are installed to create narrow passageways for the air wipingbetween the sheets 5, yet these passageways are by no means so narrow asto hold danger of getting clogged up by sedimentary deposits. The sheets5 which lill the tower unit B or G, are not to be serviced every seasonor every second season; they are designed for continual functioningduring the life of the apparatus.

It is imperative, for best results, that the corrugated metal ysheets 5be uniformly moistened. For that reason, the top edge of each sheet 5Ihas been altered in order to expose a greater area of each sheet to thefalling drops of water. Vertical incisions, about a ingers width apart,are made on the top edge of each sheet 5. Then the spaces between theincisions are bent slightly downward, alternately to the front and tothe rear, but not deep enough that the prongs would hinder the air ow.It will be noted that prongs 39 are leaning backwards, while prongs 40are leaning forward. Prongs 39 and 4% stand adjacent, on the same sheet5, but when drops of water hit them, a prong 39 will shed it to thefront side, while a prong 4t) will shed it to the rear side of the sheet5, thus assuring a uniform moistening of the sheets 5.

These corrugated metal sheets 5, however, are water repellent; they mustbe processed to tit them for effective air wiping over their furrows.Aluminum or galvanized sheet metal, fresh from the mills, has .an almostoily surface. Water rolls off the metalas olf a ducks back. The dropsthat cling, do not spread out. By Sandblasting the sheets 5 and thenapplying a porous scale by a dip in lime, cement, or similar solutions,the surface becomes more amenable. A sediment of calcium, as found inevery water kettle, makes an ideal surface for a sheet rIhe intrusion ofsuch sediments are destructive in the present day evaporative coolersfilter pads, because suoh sediments clog up their pores and, in shorttime, require the pad to be torn out and replaced, but in a cooler ofthe character described, such sediments prove an laid in spreading the'drip of water on the corrugated metal sheets 5; there is no danger ofclogging up any pores. That is why recirculation of the water by a pumpmay be safely recommended for this type of cooler.

In Fig. l is shown a cooler installed at a small dwelling C, of one ortwo rooms. No attempt is made to circulate the house air. But precoolingof the intake water has been provided.

Atop casing A is positioned a panl 7. Specially prepared metal disks,Fig. 4, are stackedupon this pan 7 and strapped thereto. These diskshave parallel slots cut in them, the ensuing strips being bent intolittle gable roofs 8. Drops of water falling on them, are spread intothin films. A marginal border 9 holds the strips together.

lt will be noted in Fig. 4 that the cutting of the slots in these disks,is by design. The H-side varies from the K-side. By this method it iseasy to ensure the placing of the eaves over the ridges of the rooflets8.

A V-trough 49 with perforations is levelled and fastened upon the stackof prepared disks. An inlet pipe 10 is overhead, bringing water whichthe V-trough 49 spills in drops upon the stacked disks. The drops ofwater, split and resplit over the rooflets 8, are turned into thinfilms. spread out and cooled readily by evaporation.

The shallow pan 7 has an outlet in its bottom, with an outlet tube 11.This tube 11 is extended downward through a hole drilled into casing A.Here a hose 12 is attached to the outlet 11, for conveying the precooledwater to a water distribution section positioned above the assembledcorrugated metal sheets 5.

The water distribution section consists of a rectangular trough 13, intowhich the hose 12 with the precooled water is led. Attached to andinserted into the rectangular trough 13. are nine or more sl-troughs 14,leading of? at right tangles from the main trough 13.

The V-troughs 14, being positioned over the assembled corrugated sheets5, spill drops of water upon the prongs 39 and 40, willich are designedto shed water to both sides of their sheet 5. See Fig. 7.

The rear edges on the sides of the tower units B or G are provided withanges 36 (Fig. 6) for a removable door 46 or 48 respectively.

There are openings cut at each side of the top casing A or F, also anopening at the rear, and removable doors provided to close upon theseopenings. They are needed for possible removal of the blowers pulley orshaft, or for the removal of the motor, also to give 4 access to thewater distribution section, and to the lubricating system.

In Fig. 2 is [demonstrated a cooler assembled from top casing F and atower unit G, connected and attached to dwelling D by the outlet duct 4of the blower 45 and by elbow duct 25 through which air is to be drawnfrom dwelling D into the tower unit G. The latter is filled withmoistened corrugated metal sheets 5.

'llhe suction created by the blower 45 forces the air in the tower unitG to surge upward, past the rounded furrows of the sheets 5. Elbow duct25, being tightly connected to the open bottom of tower unit G and tothe sump pan 21, is bound to have its air content follow the upwarddraft, and so the house air is drawn upon for circulation.

The intake air ot' the cooler illustrated in Fig. l is draw-n in throughopenings 20, near the bottom of tower unit B. Below the air intake 2t),a sump 42 is suspended from the bottom of tower unit B by rods 23. Sumppan 42 gathers the water dripping from the corrugated metal sheets 5 andpasses it out through an opening having an outlet tube 22.

The cooler illustrated in Fig. 2 has a sump pan 21 at the bottom of thetower unit G. However, the structure of this cooler, Fig. 2, involvesthe elbow duct 25, installed to draw air from dwelling D. Thisnecessitates airtight connections of the tower unit G to both the airduct 25 and to the sump pan 21.

There is a remote danger that the sump Water inpan 21 of Fig. 2 mightget clogged up in outlet 44, because the sump pan 21 is tightly attachedto the elbow duct 25. In coolers requiring pads of wood shavngs, suchstoppages :are not rare. However, if for some reason, outlet 44 of Fig.2 should clog up, the water in sump pan 21 would rise and spill throughduct 25 into the dwelling D. i

Therefore, a simple emergency water outlet flap valve 27 has beeninstalled on the side of sump pan 21. An opening 30 is cut into the sideof sump pan 21. Over this opening 30 is placed valve 27, a strip ofsheet rubber, the lower part of which is fastened to the outside of pan21 by two stove bolts 28. The part of sheet rubber which covers theoutlet hole 30, is backed by and cemented to a metal plate 29. Attachedto this piece of metal 29 and thrust through the opening 30, is a curvedmetal arm 31 bearing a wooden tloat 32. The weight of lloat 32 holds thevalve 27 airtight against the outside of sump pan 21 until the Wlatershould happen to rise in sump pan 21, causing tloat 32 to raise thecurved metal arm 31, which opens the valve 27.

Precooling of the water is omitted in the cooler illustrated in Fig. 2.An inlet water tube 17 leads directly to a tube and hose connection 18,affixed to an opening through top casing F. A ihose 19, attached to theconnection 18, leads down to trough 43 with consequent spilling of dropsof water from the V-troughs 14, as in the cooler illustrated in Fig. l.

A bracket 24 in Fig. l is a structural support fastened to tower unit Band to dwelling C.

Since the cooling obtained in this type of cooler does not requiretightly packed filter panels, there is no expense for tear-downs andreplacements each season. The material used for the wiping of the intakeair will give service through the years. It will not clog up. lt willnot disintegrate, and it will not sag. v

The intake air is made to travel a long-drawn-out course withoutencountering any treacherous leak holes which let hot air slip through.

The shaping of the corrugated metal sheets 5 with their.

rounded furrows falls in line with the direction and sweep of the airow. Enough opposition is presented by the deep rondures of the furrowsfor adequate wiping of the air, yet it is not severe enough to obstructthe air ow. Y

A threefold adjustment of the corrugated sheets 5 is available: therondures of the furrows may be altered; the spacing may be changed, andthe height of the sheets 5, as well as the height of the tower units Bor G may be adjusted.

The advantages of circulating the house air are twofold: A dwelling canbe cooled more rapidly by this method, and at a saving; humidity is helddown, because the problem of cooling the excessively h'ot outside airhas been avoided.

I claim:

l. In an apparatus of the character described, comprising a top casingof sheet metal, open at the bottom, having an air outlet and a ductleading therefrom into a dwelling to be cooled; a blower and a motorpositioned within the said casing; a tower unit, its back sideremovable, its shape like the said top casing, forming an extensionthereof downward, being fitted and attached to the open bottom of thesaid top casing; thin, corrugated metal sheets, less in height and widththan the said tower unit, their rounded furrows positioned horizontallyin the said tower unit; four angle-iron ianges fastened horizontally onthe inner sides of the said tower unit, one of the said flanges beingpositioned at the upper left side, another at the upper right side,within the said tower unit, a third ange being positioned at the lowerleft side, a fourth ange being positioned at the lower right side,within the said tower unit; slots cut in the sides of the saidcorrugated metal sheets, one near the bottom and one near the top ofeach side; spacersa in the form of metal clips, with an end protrudingat a right angle, fastened at top and bottom sides of the saidcorrugated sheets to obtain uniform spacing for them; the saidcorrugated sheets, by means of the said slots, being slid upon the saidanges into the said tower unit; means for distributing drops of waterupon the corrugated metal sheets assembled in the said tower unit; thesaid blower producing air movement upwards through the said tower unitand past the moistened furrows of the said corrugated sheets which formclosely spaced passageways moistened for the wiping and the cooling ofthe intake air, the said spacers holding the assembled sheets far enoughapart to eliminate clogging up by sedimentary scale and to eliminateseasonal replacements; vertical cuts, a ngers width apart, along the topedge of each corrugated metal sheet, the spaces between the incisionsbeing slightly bent downward, alternately forward and backward, so thata greater area of each corrugated metal sheet be exposed to the drip ofthe water, and so that uniform moistening be afforded both sides of eachcorrugated sheet; a liange bent outward from the edges at the rear ofeach side of the said tower unit; a sheet metal door aligned to the saidtwo flanges and closed upon the rear of the said tower unit after theassembly of the said corrugated metal sheets; a sump pan, suspended byrods from the bottom of the said tower unit; an outlet opening in thebottom of the said sump pan, with a water outlet pipe; and a spacebetween the open bottom of the said tower unit and the said sump pan,the intake air being swept upwards through the said space against anopposing shower of drops of water falling from the sheets in the saidtower unit; air and water striking with head-'on force, resulting in aprimary cooling of the intake air, before its Contact with the moistenedmetal sheets in the said tower unit.

2. ln an apparatus of the character described, comprising a top casing,open at the bottom, having an air outlet and a duct leading therefrominto a dwelling to be cooled; a blower and a motor positioned within thesaid casing; a tower unit, its back side removable, its shape like thesaid top casing, forming an extension thereof downward, being fitted andattached to the open bottom of the said top casing; corrugated metalsheets, their furrows positioned horizontally within the said towerunit; four angle-iron anges fastened horizontally on the inner sides ofthe said tower unit, one of the said anges being positioned at the upperleft side, another at the upper right side, a third liange beingpositioned at the lower left side, a fourth at the lower right side,within the said tower unit; slots `cut in the sides of the saidcorrugated sheets to fit upon the said flanges; spacers, in the form ofmetal clips, upon the side edges of the said metal sheets; means fordistributing drops of water upon the sheets assembled in the said towerunit; the said blower producing air movement upwards, through the saidtower unit and past the moistened corrugated sheets; vertical incisionsalong the top edge of each corrugated sheet, the spaces between theincisions being bent alternately forward and backward to obtain uniformmoistening for each side of the said sheets; a flange formed at the rearedge Iof each side of the said tower unit; a door to fit and to fastenupon the said flanges; an elbow duct connected to the open bottom of thesaid tower unit; an air duct connected to the said elbow duct, leadingthrough an opening in the wall, to draw air from a dwelling to becooled, thus adapting this evaporative cooler for the circulation of thehouse air, effecting lower humidity in the said dwelling by avoiding theintake of excessively hot outside air; an opening at the bottom of thesaid elbow duct; a sump pan built into the said opening, with airtightconnections on all four sides; an opening in the bottom of the said sumppan; a water outlet pipe afhxed therein; and an emergency water outletvalve aixed at one side of the said sump pan, to forestall a possibleclogging up and a ooding of the said elbow duct leading into thedwelling.

3. In an apparatus of the character described, comprising a top casing,open at the bottom, having an air outlet and a duct leading therefrominto a dwelling to be cooled; a blower and a motor positioned within thesaid casing; a tower unit, its back side removable, its shape like thesaid top casing, forming an extension thereof downward, being fitted andattached to the open bottom of the said top casing; corrugated metalsheets, their furrows positioned horizontaliy within the said towerunit; four angle-iron flanges fastened horizontally on the inner sidesof the said tower unit, one of the said anges being positioned at theupper left side, another at the upper right side, a third frange beingpositioned at the lower left side, a fourth at the lower right side,within the said tower unit; slots in the sides of the said corrugatedsheets to fit upon the said flanges; spacers, in the form of metalclips, upon the side edges of the Said corrugated sheets; means fordistributing drops of water upon the corrugated sheets assembled in thesaid tower unit; the said blower producing air movement upwards, throughthe said tower unit and past the moistened sheets; vertical incisionsalong the top edge of each corrugated sheet, the spaces between theincisions being bent slightly downward, alternately forward andbackward, to obtain uniform moistening for each side of the said sheets;a flange formed at the rear edge of each side of the said tower unit; adoor to fit and to fasten upon the said ilanges; an elbow duct connectedto the open bottom of the said tower unit; an air duct connected to thesaid elbow duct, leadinff through an opening in the wall, to draw airfrom. a dwelling to be cooled; an opening at the bottom of the saidelbow duct; a sump pan built into the said opening, with airtightconnections; an opening at the bottom of the said sump pan; a wateroutlet pipe aiixed therein; an emergency water outlet valve aliixed atone side of the said sump pan; a water inlet pipe atop the said topcasing, and water running therefrom to be precooled for the moisteningof the said corrugated metal sheets; a shallow pan positioned atop thesaid top casing; metal disks having slots cut into them, the ensuingstrips of metal being bent into little gable roofs, over which theintake water is to be spread out; said rooet disks being stackedhorizontally upon the said shallow pan and strapped thereto; arectangular trough leveled and fastened upon the said stack of roofletdisks, beneath the said water inlet pipe; six or more "7 perforatedV-troughs attached to and leading off at right angles from the saidrectangular main trough; said V-troughs t0 spill drops of water upon thesaid stack of rooflet disks; the said stack being designed to effect anarrangement of eaves over ridges of the rooets, thus splitting andresplitting the ow of the intake water, creating thin films of water,cooled readily by evapora tion; an outlet in the said shallow pan atopthe top casing; an outlet tube attached to the said outlet; a hoseattached to the said tube for conveying the precooled water; an openingin the said top casing to lead the said hose down through the said topcasing to a water distribution section positioned above the saidcorrugated metal sheets assembled within the said tower unit; saiddistribution section consisting of a rectangular trough into which thesaid hose with the precooled Water is led; and nine vor more perforatedV-troughs attached to and leading off at right angles from the said maintrough;

` 8 said V-troughs being positioned close over the assembled corrugatedmetal sheets, drops of water from the said perforated V-troughsproviding moisture for the rounded furrows of the said metal sheets overwhich the intake air is being swept.

References Cited in the le of this patent UNITED STATES PATENTS 586,766Haslam July 20, 1897 1,334,515 Brown Mar. 23, 1920 2,161,834 Seeley June13, 1939 2,231,088 Richardson Feb. 11, 1941 2,241,493 van Thiel May 13,1941 2,462,763 Nichtingall Feb. 22, 1949 FOREIGN PATENTS 464,433 GreatBritain Apr. 19, 1937 571,510 Great Britain Aug. 28, 1945

